Dental Instrument With a Flexible Tip End and Method of Manufacture

ABSTRACT

Dental instruments, assemblies, and components for a dental instrument are described with a two-piece tip that includes a flexible tip end and a stiff shank. Various methods of assembly are described for securing the flexible tip end to the shank including utilizing a slot in the shank and one or more pins inserted through the tip and shank, a securing material, and forming the shank with a distal portion coupled to a portion of the flexible tip end.

CROSS-REFERENCE TO RELATED APPLICATION

This application is a continuation of U.S. application Ser. No.16/372,084, filed Apr. 1, 2019, which claims the benefit of the filingdate of U.S. Provisional Application No. 62/686,493, filed Jun. 18,2018, the entireties of which are hereby incorporated by reference.

FIELD OF THE DISCLOSURE

The present disclosure relates generally to dental instruments and, moreparticularly, to dental instruments having a flexible tip end.

BACKGROUND

Dental instruments can be used to manipulate various materials which areplaced, shaped, and sculpted during procedures. Point flexibility forthese instruments is desirable as flexibility aids tremendously in thesculpting and shaping of the material. Commonly, instruments of thesetypes can be manufactured from steel. Given the metallurgic propertiesof steel, however, manufacturing instruments from steel results inrelatively rigid points. Further, if steel points are thinned and usedto manipulate materials in the desired manner, the points can break overtime, if not immediately, making them potentially unsafe to use.

SUMMARY

In accordance with a first aspect, a dental instrument is disclosed thatincludes a handle and a two-piece tip attached to the handle. Thetwo-piece tip includes a shank including a distal portion with an endsurface having a slot, where the distal portion extends along alongitudinal axis. The distal portion further has an aperture extendingtherethrough in a direction generally orthogonal to the longitudinalaxis. The two-piece tip further includes a flexible tip end having aportion that is inserted within the slot, where the portion includes anaperture that extends therethrough. A pin is configured to be insertedthrough the apertures of the distal portion and the flexible tip end tosecure the flexible tip end to the shank.

In accordance with one form, the shank can have a bent configuration,which in further forms can include first and second bends within ahorizontal plane.

In accordance with another form, the flexible tip can be made of NickelTitanium (NiTi) foil and/or can have a spatula configuration.

In accordance with another form, the apertures and pin can be sizedrelative to one another to create an interference fit and/or can havecylindrical configurations.

In accordance with another form, the apertures are first apertures, thepin is a first pin, and the dental instrument further includes a secondaperture that extends through the distal portion in a directiongenerally orthogonal to the longitudinal axis, where the second apertureis spaced from the first aperture along a length of the distal portion.A second aperture of the flexible tip end that extends through theportion thereof is also included, where the second aperture is spacedfrom the first aperture along a length of the portion. The dentalinstrument of this form further includes a second pin that is configuredto be inserted through the second apertures of the distal portion andthe flexible tip end to secure the flexible tip end to the shank.

In accordance with another form, the two-piece tip is a first two piecetip with a first shank and a first flexible tip end, and handle includesopposing first and second ends, where the first two-piece tip is coupledto the first end. In this form, the dental instrument further includes asecond two-piece tip that is attached to the second end of the handle.The second two-piece tip including a second shank including a distalportion with an end surface having a slot, where the distal portionextends along a second longitudinal axis, and an aperture that extendsthrough the distal portion in a direction generally orthogonal to thesecond longitudinal axis. The second two-piece tip further includes asecond flexible tip end having a portion inserted within the slot, theportion including an aperture extending therethrough, and a second pinthat is configured to be inserted through the apertures of the distalportion and the second flexible tip end to secure the second flexibletip end to the second shank.

In accordance with a second aspect, a dental instrument is disclosedthat includes a handle and a two-piece tip attached to the handle. Thetwo-piece tip includes a steel shank with a distal portion having an endsurface having a slot, where the distal portion extends along alongitudinal axis. The dental instrument further includes a NiTi foiltip end having a portion coupled to the distal portion of the shank. Amaterial is disposed between the portion of the NiTi foil tip end andthe distal portion to secure the NiTi foil tip end to the steel shank.

In accordance with one form, the material is one of a filler metal tosecure the NiTi foil tip end to the steel shank with a brazing processor an adhesive.

In accordance with another form, the end surface of the distal portioncan include a slot, and the portion of the NiTi foil tip end can beinserted within the slot.

In accordance with a third aspect, a method of manufacturing a dentalinstrument is disclosed that includes providing a handle and a two-piecetip attached to the handle. The two-piece tip includes a shank thatincludes a distal portion with an end surface having a slot, the distalportion extending along a longitudinal axis, and an aperture thatextends through the distal portion in a direction generally orthogonalto the longitudinal axis. The method further includes inserting aportion of a flexible tip end into the slot so that an apertureextending through the portion aligns with the aperture of the distalportion and inserting a pin through the apertures of the distal portionand the flexible tip end to secure the flexible tip end to the shank.

In accordance with some forms, the method can include one or more of:forming the aperture through the distal portion in a direction generallyorthogonal to the longitudinal axis, forming the aperture through theportion of the flexible tip end, or forming the slot through the endsurface and into the distal portion of the shank along the longitudinalaxis thereof.

In accordance with another form, the method further includes bending thedistal portion of the shank to create at least one bend.

In accordance with another form, providing the two-piece tip includesproviding the shank with first and second apertures spaced from oneanother and extending through the distal portion in a directiongenerally orthogonal to the longitudinal axis. Inserting the portion ofthe flexible tip end into the slot can include inserting a portion ofthe flexible tip end into the slot so that first and second aperturesextending through the portion align with the first and second aperturesof the distal portion, respectively. Further in this form, inserting thepin through the apertures of the distal portion and the flexible tip endincludes inserting first and second pins through the first and secondapertures, respectively, of the distal portion and the flexible tip endto secure the flexible tip end to the shank.

In accordance with a fourth aspect, a method of manufacturing a dentalinstrument is provided that includes providing a flexible tip endincluding a retaining portion and forming a shank with a distal portioncoupled to the retaining portion of the flexible tip end to secure theflexible tip end to the shank.

In accordance with some forms, the method includes one or more of:providing a flexible tip end including an aperture extendingtherethrough, 3D printing the shank around the retaining portion of theflexible tip end, injection molding the shank around the retainingportion of the flexible tip end, forming a shank in a bentconfiguration, forming a handle with the shank at one end of the handle,and deforming the distal portion of the shank to clamp down on theretaining portion of the flexible tip end to secure the flexible tip endto the shank.

BRIEF DESCRIPTION OF THE DRAWINGS

The above needs are at least partially met through provision of theembodiments described in the following detailed description,particularly when studied in conjunction with the drawings, wherein:

FIG. 1 is a perspective view of a dental instrument showing a handlewith shanks coupled to opposite ends of the handle in accordance withvarious embodiments;

FIG. 2 is a perspective view of a shank having a bent configuration anda distal portion in accordance with various embodiments;

FIG. 3 is a perspective view of a portion of a distal portion of theshank of FIG. 2 with a flexible tip secured thereto and a pin inaccordance with various embodiments;

FIG. 4 is a top plan view of a shank having a flexible tip securedthereto with a pin in accordance with various embodiments;

FIG. 5 is a perspective view of a flexible tip for a dental instrumentwith an aperture extending therethrough in accordance with variousembodiments;

FIG. 6 is a side elevational view of the flexible tip of FIG. 5 inaccordance with various embodiments;

FIG. 7 is a top plan view of the flexible tip of FIG. 5 in accordancewith various embodiments;

FIG. 8 is top plan view of a shank having a flexible tip secured theretowith a plurality of pins in accordance with various embodiments;

FIG. 9 is a perspective view of a flexible tip for a dental instrumentwith a plurality of apertures extending therethrough in accordance withvarious embodiments; and

FIG. 10 is a perspective view of a portion of a distal portion of theshank of FIG. 8 with a flexible tip secured thereto with a material inaccordance with various embodiments.

Skilled artisans will appreciate that elements in the figures areillustrated for simplicity and clarity and have not necessarily beendrawn to scale. For example, the dimensions and/or relative positioningof some of the elements in the figures may be exaggerated relative toother elements to help to improve understanding of various embodimentsof the present invention. Also, common but well-understood elements thatare useful or necessary in a commercially feasible embodiment are oftennot depicted in order to facilitate a less obstructed view of thesevarious embodiments. It will further be appreciated that certain actionsand/or steps may be described or depicted in a particular order ofoccurrence while those skilled in the art will understand that suchspecificity with respect to sequence is not actually required. It willalso be understood that the terms and expressions used herein have theordinary technical meaning as is accorded to such terms and expressionsby persons skilled in the technical field as set forth above exceptwhere different specific meanings have otherwise been set forth herein.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

Dental instruments, assemblies, and components for a dental instrumentare described herein with a flexible tip end and a stiff shank. Atwo-material dental instrument component achieves these beneficialresults by utilizing the preferred properties of the two materials. Inembodiments, the shank can be a stiff material, such as stainless steel,and the tip end can be a NiTi foil, also known as Nitinol foil. Nitinolfoil advantageously provides a flexible tip that resiliently bendswithout breaking.

Example configurations and components for a dental instrument 10 areshown in FIGS. 1-10. As shown in FIG. 1, the dental instrument 10includes a handle portion 11 having a shaft configuration for a user togrip and manipulate the dental instrument 10. The handle portion 11 hasopposite first and second ends 14, 16 that can be configured to have ashank 12 coupled thereto, if desired. In the illustrated form, the firstand second ends 14, 16 have a tapered configuration to provide atransition to the relatively smaller diameter of the shank 12.

An example shank 12 is shown in FIG. 2 that includes a coupling endportion 17 configured to engage one of the ends 14, 16 of the handle 11,a tapering portion 18, first and second bends 20, 22, an intermediateportion 24 extending between the first and second bends 20, 22, and adistal portion 26 extending from the second bend 22 to a distal end 28of the shank 12. The tapering portion 18 decreases a diameter of theshank 12 from adjacent to the handle 11 to the relatively smallerdiameter intermediate and distal portions 24, 26, which can have agenerally constant diameter.

The first bend 20 directs the shank 12 along a horizontal plane awayfrom a longitudinal axis L (FIG. 1) of the handle 11 and the second bend22 directs the shank 10 along the horizontal plane back towards thelongitudinal axis L of the handle 11. In the illustrated form, thesecond bend 22 is a generally 90 degree bend and the intermediateportion 24 has a longer longitudinal length than the distal portion 26,such that the distal end 28 of the shank 10 is spaced from thelongitudinal axis L of the handle 11 along the horizontal plane. Ofcourse, other bend and length configurations are within the scope ofthis disclosure.

The distal end 28 of the shank 12 includes opposing planar sides 30extending inwardly with respect to one another to a rectangular endsurface 32. With the distal portion 26 being cylindrical, in theillustrated form, the planar sides 30 have a parabolic shape. A slot 34with an opening 36 disposed along the end surface 32 extends within thedistal portion 26 along a longitudinal axis X (FIG. 2) thereof to adesired depth. In the illustrated form, the slot 34 extends through thewidth of the distal end 28. In one example, and as depicted in FIG. 3,the slot 34 may further include openings 38 along an exterior 40 of thedistal portion 26. The slot 34 can be cut into the distal end 28 of theshank 12 in a hatchet and/or hoe orientation by an electric dischargemachining (EDM) wire, micro saw blade, mill, and so forth.

A tip end 42 is coupled to the distal end 28 of the shank 12 to providedesirable characteristics for a particular dental procedure. By oneapproach, and referring now to FIGS. 5-7, the tip end 42 is a spatulatip having a thin planar body 44 with a curved forward portion 46 and arectangular rear portion 48. As discussed above, the shank 12 and tipend 42 are different materials and, as such, are secured together with asuitable method, examples of which are described below with reference toFIGS. 2-10. The tip end 42 also includes an aperture 54 extendingthrough the rear portion 48 and corresponds to an aperture in the distalend 28 of the shank 12, as described more below.

In each securing example, the tip end 42 is inserted into the slot 34 tomount to the distal end 28 of the shank 12. The orientation of theplanar sides 30 with respect to the horizontal plane can provide a hoeorientation for the tip end 42 or a hatchet orientation for the tip end42, as desired. In addition, in each example, the shank 12 may comprisea stiff material, such as stainless steel, and the tip end 42 maycomprise a NiTi foil, also known as Nitinol foil.

In one form, the dental instrument 10 includes shanks 12 on both sides14, 16 of the handle 11 with one shank 12 having distal end 28 with ahoe orientation where the tip end 42 is generally orthogonal to thehorizontal plane and the other shank 12 having a distal end 28 with ahatchet orientation where the tip end 42 is generally parallel with thehorizontal plane to provide a user with both functionalities. Further,if desired, the tip end 42 and slot 34 can be configured so that forwardportion 46 of the tip end 42 extends to intersect the longitudinal axisL of the handle 11 so that a user has precise manipulation of the tipend 42.

In a first embodiment, shown in FIGS. 2-7, the tip end 42 is secured tothe distal end 28 of the shank 12 with a pin 50. More specifically, thedistal end 28 of the shank 12 has an aperture 52 extending radiallythrough a portion thereof including the slot 34 in a direction generallyorthogonal to the longitudinal axis X of the distal portion 26. Theaperture 54 of the tip end 42 corresponds to the aperture 52 of thedistal end 28 of the shank 12. So configured, with the rear portion 48inserted into the slot 34, the pin 50 can be inserted through both theaperture 52 and the aperture 54 to secure the tip end 42 to the shank12. By one approach, the pin 50 can have a cross-section dimensiongreater than one or both of the apertures 52, 54 so that the insertionof the pin 50 therethrough creates an interference fit. Further, the pin50 can be permanently joined to the shank 12 by swaging and grinding anouter surface 56 of the pin 50 so that the outer surface 56 is smoothand aligned with adjacent portions of the shank 12. In the illustratedform, the pin 50 and apertures 52, 54 are cylindrical. Of course, othershapes and configurations can alternatively be used. For example, thepin 50 and apertures 52, 54 can have a cross-section shape to aid inresisting rotation of the tip end 42, such as a triangle, square, star,ovular, and so forth.

In a second embodiment, shown in FIGS. 8 and 9, the shank 12 has aconfiguration similar to the above embodiment and, as such, only thedifferences will be described. In this form, the tip end 42 is securedto the distal end 28 of the shank 12 with a second pin 58 in addition tothe first pin 50. As such, the distal end 28 of the shank 12 has asecond aperture 60 that extends radially through a portion thereofincluding the slot 34 in a direction generally orthogonal to thelongitudinal axis X of the distal portion 26. The second aperture 60 isspaced from the first aperture 52 along a length of the distal portion26. The tip end 42 includes a corresponding second aperture 62 thatextends through the rear portion 48 thereof, as depicted in FIG. 9. Soconfigured, with the rear portion 48 inserted into the slot 34, thesecond pin 56 can be inserted through the aligned second apertures 60,62 to further secure the tip end 42 to the shank 12. Using a pluralityof pins 50, 58 accommodates a larger tolerance stack when installing thetip end 42 to the shank 12, which advantageously results in moreefficiencies during manufacturing. For example, the length of the tiprear portion 48 is on the shorter end of the tolerance and the depth ofthe shank slot 34 is on the larger end of the tolerance, a gap wouldexist that would allow for rotation of the tip end 42. Using two or morepoints to secure the tip end 42 to the shank 12 prevents tip rotation insuch a tolerance scenario.

By one approach, the second pin 58 can have a cross-section dimensiongreater than one or both of the second apertures 60, 62 so that theinsertion of the second pin 58 therethrough creates an interference fit.Further, the second pin 58 can be permanently joined to the shank 12 byswaging and grinding an outer surface 64 of the second pin 58 so thatthe outer surface 64 is smooth and aligned with adjacent portions of theshank 12. In the illustrated form, the second pin 58 and apertures 60,62 are cylindrical. Of course, other shapes and configurations canalternatively be used. For example, the pins 50, 58, and apertures 52,54, 60, 62 can have a cross-section shape to aid in resisting rotationof the tip end 42, such as a triangle, square, star, ovular, and soforth. Further, although only two pins are shown, it will be understoodthat additional pins can be utilized and configured in a similar manner.

In a third embodiment, the slot 34 can have a wider configurationrelative to the thickness of the tip end 42 as compared to the aboveembodiments. This allows the tip end 42 to be inserted into the slot 34with little to no resistance. After the tip end 42 has been insertedinto the slot 34 to a desired depth, a user can then pinch the planarsides 30 of or otherwise physically deform the distal end 28 of theshank 12 to clamp down on the tip rear portion 48 to secure the tip end42 to the shank 12. This clamping action can be achieved by the use ofany suitable tools.

In other embodiments, shown in FIG. 10, the tip rear portion 48 can beinserted into the slot 34 and secured therein using a third material 66.In a first example, the third material 66 is an adhesive disposed withinthe slot 34 or applied to the tip rear portion 48. In a second example,the third material 66 is a filler metal flowed into the joint betweenthe tip end 42 and shank 12 in a brazing process. Utilizing an adhesiveor a brazing process secures the tip end 42 to the shank 12 without theadded steps and components of the above embodiments including formingthe apertures 52, 54, 60, 62 and inserting the pins 50, 58. Of course,an adhesive or brazing process can alternatively be used in combinationwith the pin embodiments discussed above to ensure that the tip end 42is securely coupled to the shank 12.

A stainless steel shank provides several advantages, including: astiffness that provides maximum control and manipulation of the tip endfor a user, good material formability enabling a two-bend shankconfiguration that allows a user access and visibility inside apatient's mouth, no reduction in appearance or strength of the shankafter being sterilized multiple times, patient bio-compatibility, and arelatively low cost manufacturing to obtain a desired shank geometry.

A Nitinol foil tip end provides several advantages, including:superelastic flexibility at room temperature, about 10-30 times ordinarymetal, for spreading and controlling composite onto a tooth, implantsurface, or other application location, very good strain recoveryallowing for excellent kink resistance even at very aggressive bendangles, an advantageous shape memory effect allowing the foil to recoveran original shape upon heating above a transformation temperature afterbeing deformed at a lower temperature, the Nitinol foil tip can be cutinto a variety of tip end shapes allowing for a range of surface accessand orientations, ability to sterilize the instrument multiple timeswith no reduction in appearance, flexibility, or strength, and patientbio-compatibility.

Those skilled in the art will recognize that a wide variety ofmodifications, alterations, and combinations can be made with respect tothe above described embodiments without departing from the scope of theinvention, and that such modifications, alterations, and combinationsare to be viewed as being within the ambit of the inventive concept.

For example, the shank 12 can alternatively be composed of plastic,coated steel, or other suitable rigid material. Additionally, the shank12 may be 3D printed into a desired shape, such as the two bendconfiguration described above, out of a suitable material, includingsteel, plastic, or other rigid material. Alternatively, the shank 12 canbe injection molded into a desired shape. Further, if desired, the shank12 can be 3D printed or injection molded around a flexible tip end 42configured as described above. The tip end 42 can include a retainingportion, such as the apertures 54, 60 described above, or otherprotrusion(s) and fixed in position as the shank 12 is 3D printed ormolded therearound. With the retaining portion, the tip end 42 can befixedly secured to the shank 12. Still further, the tip end 42 may becomposed of an alternate material, such as plastic, stainless steel, ora coated steel.

What is claimed is:
 1. A dental instrument comprising: a handle; a tipattached to the handle, the tip including: a shank including a distalportion extending along a longitudinal axis, the distal portion havingan end surface and a slot having an opening along the end surface andextending rearwardly therein along the longitudinal axis; a tip endhaving a rear portion disposed within the slot and a forward portionextending forwardly away from the distal portion of the shank along thelongitudinal axis thereof; and a material disposed within the slotbetween the rear portion of tip end and the distal portion of the shankto secure the tip end to the shank.
 2. The dental instrument of claim 1,wherein the material comprises a filler metal to secure the tip end tothe shank with a brazing process.
 3. The dental instrument of claim 1,wherein the material comprises an adhesive.
 4. The dental instrument ofclaim 1, wherein the tip end comprises a foil.
 5. The dental instrumentof claim 4, wherein the foil has superelastic flexibility at roomtemperature.
 6. The dental instrument of claim 4, wherein the foilcomprises a Nickel Titanium foil.
 7. The dental instrument of claim 1,wherein the tip end comprises a spatula.
 8. The dental instrument ofclaim 7, wherein the forward portion of the tip end has a curvedconfiguration and the rear portion has a rectangular configuration. 9.The dental instrument of claim 1, wherein the shank comprises a steelshank.
 10. The dental instrument of claim 1, wherein the materialprovides the only securing mechanism to secure the tip end to the shank.11. The dental instrument of claim 1, wherein the slot extends entirelythrough the shank in a direction perpendicular to the longitudinal axisforming longitudinal openings along an exterior thereof.
 12. The dentalinstrument of claim 1, wherein the end surface extends transverse to thelongitudinal axis of the distal portion of the shank.
 13. The dentalinstrument of claim 12, wherein the end surface has a rectangularconfiguration.
 14. The dental instrument of claim 1, wherein the distalportion includes opposed tapering side surfaces extending to the endsurface thereof.
 15. The dental instrument of claim 14, wherein theshank comprises a cylindrical body, the tapering side surfaces having aparabolic configuration.
 16. A method of manufacturing a dentalinstrument, the method comprising: providing a flexible tip end having aflat body with opposing planar main surfaces, the body including aretaining portion in a proximal end thereof; and forming a shank by atleast one of 3D printing or injection molding around the retainingportion of the body, such that a distal portion of the shank is coupledto the retaining portion of the body to secure the flexible tip end tothe shank, the shank configured to be coupled to a handle.
 17. Themethod of claim 16, wherein the retaining portion of the body comprisesone or more apertures extending therethrough; and forming the shankcomprises at least one of 3D printing or injection molding materialthrough the one or more apertures to secure the flexible tip end to theshank.
 18. The method of claim 16, wherein the retaining portion of thebody comprises one or more protrusions extending outwardly from thebody; and forming the shank comprises at least one of 3D printing orinjection molding material around the one or more protrusions.
 19. Themethod of claim 16, wherein forming the shank comprises forming a shankin a bent configuration.
 20. The method of claim 16, wherein forming theshank further comprises forming a handle with the shank at one end ofthe handle.